Zero Borderlands Helmet

zalus

New Member
Hey everyone!
I recently started to work on a Borderlands 2 Zero costume.
The ultimate goal of this project is to make a head to toe body suit, helmet, and a replica of the sword he uses.
Heres what I got so far!

this is to give you an idea if you dont know the character.
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I found these two images floating on the internet, no idea who made them, but if you know tell me so I can credit them!
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So, I started by printing out and measuring up some stencils, which I would eventually transfer onto some MDF board.
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I then measured cuts in each cutout to slip each piece into each other and made a sort of skeleton. then glued it together.
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Soon after I cut some pieces of insulation foam to fill in the negative spaces.
I cut curved pieces, but I realized shortly after that just cutting block pieces would have made fitting them in easier.
I glued them in using Gorilla Glue wood glue.
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NOTE! Ive read that using Liquid Nails would be a more reliable choice, but I have had no issue so far with the glue I used.
After the glue dried, I began to sand down the blocky shape into what would be closer to the final shape.
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Shortly after getting it as close to the shape, at least the shape that pleased me enough to continue, I began to seal the foam with just acrylic paint. Reason is Bondo and clay seems to have a difficult time sticking to the foam. Sealing up the foam with acrylic makes that much easier!
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So next Ill have to sand all this bondo down, use some spot filler in spots that are still a little uneven. After that Ill use some apoxy sculpt and clay.

Then sand sand sand.
 
Neat! This seems to be a very different approach than I've seen others using. I'm quite interested in seeing how it turns out!
 
that is really great man, can you post the other stencils you used besides the front shot of the helmet and the side shot. the other ones you made out of wood. if you can, if not that is cool
 
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